Method of making a reinforced plastic lintel

ABSTRACT

AN IMPROVED METHOD OF MAKING IN A MASONRY BLOCK WALL A LINTEL OVER AN OPENING WHEREIN A PLASTIC FILM IS POSITIONED ACROSS THE LINTEL OPENING AND ADHERING ON SAID FILM A THIN GLUE LINE AFTER WHICH THE BUILDING BLOCKS ARE ADHERED TO THE FILM THUS FORMING THE LINTEL.

p 1971 A. H. WUNVDERLICH ETAL Q 3,605,372

METHOD OF MAKING A REINFORCED PLASTIC LINTEL Filed Nov. 8. 1966 23 I I2 3 l4 I5 24 l I I I I J /H 1 y T l BLOCKS L'NTEL MORTAR l 2| I0 20 22 a INVENTORS PATENT ATTORNEY United States Patent 3,605,372 METHOD OF MAKING A REINFORCED PLASTIC LINTEL Arthur H. Wunderlich, Colonia, and Roman Slysh, Scotch Plains, N.J., assignors to Esso Research and Engineering Company Filed Nov. 8, 1966, Ser. No. 592,861 Int. Cl. E04b 1/16; E040 2/10 US. Cl. 52-747 7 Claims ABSTRACT OF THE DISCLOSURE An improved method of making in a masonry block wall a lintel over an opening wherein a plastic film is positioned across the lintel opening and adhering on said film a thin glue line after which the building blocks are adhered to the film thus forming the lintel.

The present invention is broadly concerned with improved structures such as walls, buildings, and the like and with a technique of rapidly and economically erecting such structures and buildings. The invention is more specifically concerned with the utilization of a plastic lintel in place of conventional lintels such as wood, steel and the like. In accordance with a particular technique of the present invention, a unique roll-on mortar is used in conjunction with the plastic lintel for securing the respective block courses whereby effective sealing is secured by a glue line rather than by a. usual separation using conventional mortar. Furthermore, the roll-on mortar used in the present invention, in conjunction with the plastic lintel, not only securely affixes the respective courses but also may be used to seal the exterior faces of the building elements such as building blocks. This will produce a waterproof surface having a very high structural skin strength. The improved mortar also may be utilized on the inner surface to secure a decorative and pleasing aesthetic value. Also another great value is that the mortar may be used to erect structures at temperatures below 40 F. and since there is no water present in the mortar, moisture will not be absorbed by the masonry which tends to decrease mechanical strengths. Thus, a specific adaptation of the present invention is to utilize a plastic lintel rather than a conventional lintel particularly in conjunction with a glue line type mortar, and particularly in conjunction with structural members comprising finely divided aggregate bound by a bituminous binder.

In the building and construction industry it is well known that a considerable amount of the cost of erection is the labor cost, especially when erecting masonry-type walls and the like. This is due to the fact that the time required to erect a conventional wall or structure is appreciable. Also by conventional techniques utilizing a cemen titious mortar, a relatively thick layer of mortar is positioned between the respective blocks and the respective courses. If the exterior of the wall is to be rendered waterproof, a different material is used, usually an asphalt base material. This means that the excavation must be somewhat larger in order to allow a workman to work between the erected wall and the excavation in applying the exterior sealing coat. This further increases the cost of excavating and in the amount of effort required to backfill. Furthermore, if it is desired to apply a coating to the interior of the wall for sealing or for aesthetic values a third different type of coating is used. The present invention is concerned with a high speed erection system utilizing a roll-on type of mortar wherein a skin-type of seal is secured between the respective blocks and the respective courses. Also, when the sealing coat is applied to affix the respective blocks, these blocks may be rolled on both the exterior and interior surfaces in order to waterproof the exterior surfaces and to secure a desired aesthetic and pleasing skin on the interior surfaces. It is also known in the art to use as lintel members wood structures and steel structures. The wood structures are subject to deterioration as are the metallic structures which are particularly subject to corrosion.

The present invention utilizing a reinforced plastic lintel is very desirable in that it makes for simplicity of construction, is more economical, and the lintel acts as flashing which prevents water from collecting and penetrating into the wall.

A preferred method of construction is to erect a supporting form across the opening in which the supporting form has the same width as the wall. This supporting form is then covered with a plastic film such as polyethylene. The mortar of the present invention, which is also used in the wall construction, usually is then applied on the top surface of the plastic film. The fiber glass tape having the same width as the wall as, for example, about 12 inches. is then placed on the top of the coated plastic film. This will saturate the undersurface of the fiber glass to impart greater strength to the fiber glass. Sufficient mortar is also applied to the top surface of the fiber glass in order to fully saturate the fiber glass. The building blocks are then positioned on the impregnated fiber glass across the opening in the usual manner. The respective ends of the fiber glass can then be folded upwardly or downwardly on the ends of the building blocks after these ends have been coated with additional mortar in order to obtain good contact between the impregnated fiber glass and the block. Under usual conditions the structure will set in about 24 hours but is completely set in about 72 hours. The supporting structure of wood and plastic film is then removed.

The structure of the present invention may be fully understood by reference to the drawing illustrating one embodiment of the same. A typical wall structure is illustrated by blocks 21, 10, 20, and 22 having an opening thereinbetween, for example, of about 48 inches. In accordance with the present invention after removal the supporting structure will have a fiber glass reinforced plastic lintel 16 extending over the opening between blocks 10 and 20. Other blocks 11 to 15 comprising part of the lintel are supported by the plastic lintel as illustrated. The ends of the plastic lintel may be folded upwardly between blocks 23 and 11, and between blocks 15 and 24. On the other hand, the respective ends of the fiber glass may be folded downwardly between blocks 21 and 10, and between blocks 20 and 22.

While the invention may be applied to various types of structural members, it is particularly adapted for the utilization with structural members as described in Ser. No. 324,075 filed Nov. 15, 1963 entitled, Finely Divided Aggregate Binder Structural Members, inventors D. T. Rogers and J. C. Munday, and as described in Ser. No.

3 557,994 filed June 16, 1966, inventor Kamil Sor entitled, Amine Treat-mentBuilding Materials.

Thus the present invention is concerned with a timesaving erection lintel system which preferably uses solid compositions or blocks comprising 330%, preferably about 5.5% to 12%, by weight of a bituminous binder such as asphalt which is mixed with a subdivided solid such as clay and which is then compressed to a theoretical density in the range from about 70 to 98% preferably to a theoretical density in the range from about 80 to 95%. The compressed product is heat cured in an oxidizing atmosphere at a temperature in the range from about 250 to 550 F., preferably from about 360 F. to 500 F., for a period of time from about 1 hour to 10 days, preferably from about 4 hours to 80 hours and, most preferably, from 8 hours to 24 hours. For example, very high quality products are secured when treating at a temperature in the range from about 375 F. to 400 F. for a period of from about 4 to 16 hours, such as about 10 hours.

The improved mortar used in the present invention is a resin-based mortar which is applied with a paint-type roller preferably to the asphalt blocks as described. Preferred mortars are furfuryl alcohol resin-based mortars and an unsaturated polyester resin-based mortar. These materials can be easily applied over a wide range of temperatures to produce strong and damp-proof walls.

Satisfactory furfuryl alcohol resin mortars are listed in Table 1, as follows.

TABLE 1.-COMPOSITION OF FURFURYL ALCOHOL RESIN-BASED MORTARS Mortar, wt. percent 1 Applicable at temperatures above 60 F. 2 Applicable a temperatures between 40-60 F. 3 Properties:

Flash point, tag open cup, F

Specific gravity at 25 C 4 (3., avg. 1 210 Cp. viscosity at 25 0., cp. avg... 200 p1I50/50 in water, avg. 4. 5

Molecular wt The resin is a stable material with little or no tendency to advance or change in viscosity provided it is stored in a cool place. Optimum storage conditions are preferably below 75 F.

4 Imparts thixotropie properties to the mortar.

5 White silica (120 mesh).

6 Salt of p-tolucnc sulionie acid and aniline (00%) and coke flour (10%).

These mortars were prepared by mixing all components except the catalyst using a high speed mixer to assure proper dispersion of the finely divided pyrogenic silica. The catalyst was added immediately before the mortar was used. Batches of various sizes were prepared depending upon the job size. The pot life (usable working time) of the mortars varied depending upon the ambient temperature. It was found, however, that in all cases the pot life was at least one hour which represents sufficient time for the laying of a satisfactory number of blocks. The curing time of the mortars was completed within 72 hours.

Satisfactory polyester-based mortars are listed in the following Table 2:

TABLE 2.COMPOSITION OF POLYESTE R-BASED M0 RTA RS* Mortar, wt. percent Range, wt.

Component C D E percent Polyester resin 480 1 42. 0 22. 0 60-10 Polyester resin 4920 48. 0 22. 0 60-10 Pyrogenic silica 1. 6 1. 0 1. 3 0. 5-5. 0

Styrene and 2% wax 3.0 3. 0 3. 0 1 0-10. 0

UV-9 light absorber 4 0. 1 0. 1 0. 0-0. 5

60% T102 solution in polyester. 7. 0 7. 0 7. 0 3. 0-10. 0

Silica-ground sand mesh) 46. 0 40. 2 44. 2 30. 0-60. 0 MEKP 5 (30% solution in dimcthyl phthalate) 0. 4 O. 4 0. 4 0. 1-1. 0

1 Readily cured at room temperature by the addition of 0.25-1. 0% methyl ethyl ketone peroxide.

Typical properties of W laminates (see note):

Ultimate flcxnral strength, flatwise, p.s.1 Flexural modulus of elasticity, p.s.i. X 10 Ultimate tensile strength, p.s.i Elongation at break, percent 24, ooesaooo 1. 3-1.5 15, 000-17, 000

Ultimate compressive strength, fla W156 p. 40, 000-45, 000 Water absorption, 24 hr., 77 F., percent 0. 15-0. 25 2 Physical properties- Properties of liquid resin:

Viscosity at 77 F., poises 4. 5-5. 0 28-30 1. 140

Uncatalyzed stability at 77 F., rmn., months 12 Gel time at 77 F. in minutes:

Using 1% benzoyl peroxide 10-15 Using 1% MEK peroxide 5-6 Properties of unfilled casting:

Hardness, Shore Durometer A 80-85 T ensile strength 5 Elongation in tension, percent. 1135.;

pecific gravity 3 Paratfin wax, M.P. F. 4 2hydroxy-4-methoxybenzophenone. fi MeglanlglK ethyl ketone peroxide f P WE 1%escribed generally in Polyester Resins by John R. Lawrence, published by Reinhold Publishing Corp., New York.

No'rn.2 plies 1% ounce mat.

(may vary from 1-60% by The preparation of the polyester mortars is the same as that for the preparation of furfuryl alcohol mortars. Methyl ethyl ketone peroxide acts as a polymerization initiator.

Thus, the present invention is concerned with a high speed erection system which provides a strong, attractive damp-proof wall structure at a low overall cost. While the system may be used utilizing various types of blocks, such as concrete blocks, it is particularly adaptable for use with bituminous bonded blocks as described. It is preferred that the first course be laid with cementitious mortar in order to eliminate irregularities in the footing. This course is laid with care making sure it is properly aligned, leveled and plumbed. The organic base mortar is prepared as described and is applied by rolling the top course and the ends of the blocks which are placed in the next course. The block accuracy should be 1%2 inch, preferably of an accuracy of an inch.

In order to further illustrate the invention, the following examples are given.

EXAMPLE I Two identical wall structures were constructed. With respect to one wall structure, the conventional technique was used whereas in the second wall structure the technique of the present invention was used. The amount of time saved is shown in the following Table 3.

TABLE 3.-MASON LABOR REQUIRED TO BUILD IDENTI- OAL BLOCK STRUCTURES BY TWO DIFFERENT SYSTEMS Conventional concrete block,

Roller applied trowel applied polyester mortar mortar Total mason time, units 10. 15 27. 84 Savings, percent of conventionaL 64 Base From the above it is apparent that the time saved in the erection of the structure utilizing the present technique is very substantial.

EXAMPLE II The resin-based mortars of the present invention show very high bonding strengths, compressive strengths, and tensile strengths. They have a very low water absorption as compared with the conventional cement mortars. This is illustrated by the data presented in Table 4 following.

TABLE 4.-TRANSVERSE LOAD DATA WALLS,1b,/Sq.ft.*

Breaking load, 11).] Building material Mortar Condition sq. ft.

8" cinder block. Conventional cement. Dry 10 Do o 8 bitumen block. A furiuryl mortar Dry... 130 Do do Wet 120 C polyester mortar.. Dry." 113 Do "do Wet 106 Do D polyester mortal- Dry.:

1 Tested after spraying with water for 24 hours.

2 The composition is given in Table 1.

3 The composition is given in Table 2.

*Wall tested according to procedure outlined in ASTM-72.

EXAMPLE III In order to test the adhesion of the lintel of fiber glass in conjunction with the preferred asphalt blocks and in conjunction with the preferred mortar, the bond strength between the two materials was measured utilizing the modified ASTMC321 procedure. These measurements were carried out under dry and wet conditions. In both cases the bond strength was greater than 230 p.s.i. with the failure occuring in the building blocks (flexural failure). These results clearly demonstrate the excellent performance of the fiber glass reinforced polyester lintel.

While the preferred method to secure the thin glue line is by rolling on the glue or adhesive, it is to be understood that other techniques such as brushing and spraying can also be used to secure the thin glue line. Also, while the preferred adhesives are selected from the class consisting of furfuryl alcohol resins and unsaturated polyester resins, it is to be understood that other adhesives may be used such as epoxies and polyurethane adhesives. For example, other resins which may be used as adhesives include:

Epoxies (epoxy-esters, epoxy-amines, epoxy-polyamides, coal tar epoxies, phenolic epoxies, epoxy-polysulfides, epoxy-acrylic); unsaturated polyesters crosslinked with such monomers as styrene, diallyl phthalate, vinyl toluene, methyl methacrylate, triallyl cyanurate, etc.; polyurethanes and isocyanates (glycol, polyamine, polyether, polyester, or castor oil-based); phenoxy-di-isocyanates,

and furane resins (furfuryl alcohol, furfuryl alcohol-furfural, furfuryl alcohol-formaldehyde). The resins can be used either alone, or they can be extended with various fillers and/ or additives to impart specific properties.

While the fiber glass is the much preferred plastic lintel, other reinforcing materials can be used in the construction of the new lintel. These include any fibrous fillers with high tensile strength, e.g., asbestos (chrysotile, crocidolite, amosite), cotton, metals, carbon, and a variety of synthetic fibers, such as rayon, cellulose acetate, nylon, acrylics, polyesters, polypropylene, etc. Other fibrous fillers which can be used in the construction of the plastic lintel include boron, graphite, quartz (fused silica), paper and polyamide.

What is claimed is:

1. Improved method for the erection of a masonry wall structure having an opening comprising a lintel and individual building blocks which comprises placing a form across the opening, covering the form with a plastic film so as to provide support for a fiber glass tape, stretching a fiber glass tape across the opening on top of said plastic film and adhering on said fiber glass tape a thin glue line of adhesive, thereafter positioning building blocks on top of said fiber glass tape, and removing the form and the plastic film after setting has occurred so as to provide a lintel over the opening.

2. Method as defined by claim 1 wherein said blocks comprise 3 to 30% by weight of a bituminous binder and which are compacted to a theoretical density in the range from about 70 to 98% and thereafter heat cured in an oxidizing atmosphere at a temperature in the range from about 360 to 500 F.

3. Method as defined by claim 1 wherein said plastic film comprises fiber glass.

4. Method as defined by claim 3 wherein said adhesive is selected from the class consisting of furfuryl alcohol resins, unsaturated polyester resins, and epoxy resins.

5. Method as defined by claim 4 wherein said adhesive is a mortar which comprises about 40 to 70% by weight of furfuryl alcohol resin, from about 0.3 to 5.0% by weight of pyrogenic silica, from about 60 to 20% by weight of silica and from about 0.5 to 15% by weight of an acid catalyst.

6. Method as defined by claim 4 wherein said polyester resin consists of about 60 to 10% by weight of a polyester resin, from about 0.5 to 5.0% by weight of pyrogenic silica, from about 1.0 to 10% by weight of styrene, and from about 30 to 60% by weight of ground sand.

7. Method as defined by claim 4 wherein said epoxy resin consists of about -20% by weight of an epoxy resin, 3-70% by weight of an amine or polyamide hardener, 0.5-5.0% by weight of pyrogenic silica and from about 20 to 80% by weight of ground sand.

References Cited UNITED STATES PATENTS 1,370,160 3/1921 Schenk 52-408 2,718,829 9/ 1955 Seymour et a1 52-309 2,951,006 8/1960 Rubenstein 52-232 3,078,249 2/ 1963 Russell 260-860 3,236,015 2/1966 Rubenstein 52-232 3,281,256 10/1966 Rogers et a1. 94-23 3,284,946 11/ 1966 Christiansen 46-19 3,368,316 2/ 1968 Crowder 46-19 FRANK L. ABBOTT, Primary Examiner J. L. RIDGILL, JR., Assistant Examiner U.S. Cl. X.-R. 52-204, 309 

